Automated process control laboratory experience: Simultaneous temperature and level control in a continuously stirred tank reactor system

Tennyson, G. T.; Maase, E. L.; Levinson, Joshua A.

Automated process control laboratory experience: Simultaneous temperature and level control in a continuously stirred tank reactor system

Abstract

A process control laboratory experience has been developed using a continuously stirred tank
reactor system that permits simultaneous level and temperature control using water as the
process medium. This work was originally completed as a senior honors thesis project, and the
resulting system has been successfully incorporated into the process control block of a juniorlevel
unit operations laboratory course. Use of the apparatus over multiple laboratory sessions
provides students with a hands-on experience that illustrates the concepts of system
characterization (e.g., calibration, determining operating ranges, understanding
electromechanical component specifications, etc.), open-loop process response measurements,
and closed-loop response and PID tuning. A controller program to interface with the valves and
sensors and to perform data logging was constructed in LabView, employing a graphical user
interface. As part of the experience, all sensors and valves of the system are to be characterized
and calibrated. The two system processes—i.e., temperature and height—are run in an open loop
manner, with data collection providing a means to determine appropriate process models.
Process parameters from these models permit the estimation of controller tuning values (i.e.,
controller gain and time constants) through formula- or software-driven means (e.g., Control
Station Loop-Pro). SISO configurations are then employed to test various control settings for
tuning purposes, with the use of hand-tuning techniques to refine these values. The system can
ultimately be operated in a MIMO configuration without and with decoupling gains; the typical
oscillatory behavior without decoupling is demonstrated due to the inherent process interactions.
Students who use this system are thereby given a hands-on opportunity to practice a variety of
essential process control techniques and concepts, providing important context for this material.
Student assessments conducted prior to and after using this and other hands-on systems indicate
marked improvement in understanding and comfort-level for process control applications.

Title	Automated process control laboratory experience: Simultaneous temperature and level control in a continuously stirred tank reactor system
Creator	Tennyson, G. T.
	Maase, E. L.
	Levinson, Joshua A.
Publisher	ASEE Annual Conference and Exposition Proceedings
Academic Department	Chemical & Biomolecular Engineering
Division	Engineering
Organization	Lafayette College
Date Issued	2014
Date Available	2015-05-14T17:43:44Z
Type	Article
Language	English
Bibliographic Citation	Levinson, J. A., E. L. Maase, and G. T. Tennyson (2014) "Automated process control laboratory experience: Simultaneous temperature and level control in a continuously stirred tank reactor system." ASEE Annual Conference and Exposition Proceedings. Paper 8705.
Standard Identifier	Handle 10385/1898
Permalink	http://hdl.handle.net/10385/1898
Rights Statement	In Copyright
Rights Holders	American Society for Engineering Education